Process for Hydrating Hemp for Making Hemp Pre-Rolls Therefrom

ABSTRACT

A process for hydrating plant material in a hydration machine for use in a cigarette rolling machine includes the steps of measuring the moisture level of the plant material, introducing the plant material into the hydration machine, configuring hydration settings for the hydration machine to reach a target range of moisture between about 9.5% by weight and about 11.5% by weight at the exit of the hydration machine. And misting the plant material with one or more terpenes. The process further includes the steps of re-measuring the moisture level of the plant material at the exit of the hydration machine, and if the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range, removing the plant material from the hydration machine. But if the moisture level of the plant material at the exit of the hydration machine is not within about 0.5% by weight of the target range, the process further includes the steps of re-introducing the plant material into the hydration machine, re-configuring the hydration settings to reach the target range at the exit of the hydration machine, and repeating the re-measuring step as needed until the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Ser. No. 63/064,026, filed on Aug. 11, 2020, and incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to a process for hydrating hemp material for making hemp pre-rolls therefrom. More specifically, the present invention relates to a process for hydrating hemp material for making hemp pre-rolls therefrom using a conventional cigarette rolling machine.

BACKGROUND

Hemp and related hemp-like plants have been smoked for centuries. However, because material derived from hemp and related hemp-like plants includes a sticky resin, making hemp pre-rolls in a cigarette rolling machine from hemp and related hemp-like plant material has been problematic. In fact, known technology for processing materials from hemp and related hemp-like plants through a conventional cigarette rolling machine is entirely inadequate. Invariably resins from the hemp and related hemp-like plant material coats working parts of any cigarette rolling machine, which fouls the rolling machine, slowing or entirely jamming its operation, resulting in the hemp material not being processed correctly through the rolling machine into hemp pre-rolls or the rolling machine entirely ceasing to function.

The issue of sticky resin from hemp and related hemp-like plant materials fouling a cigarette rolling machine is known in the art. For example, Swiss patent application CH714395 discloses adding hemp to tobacco in limited quantities in a cigarette rolling machine noting that because the hemp has resins that stick to the machinery the hemp has to be used in limited quantities or at the end of the machine. Known efforts to process hemp and related hemp-like plant material through a conventional cigarette rolling machine have focused on treating or modifying the machine to minimize the effects of the sticky resins. For example, US Publication 2017/0188623, which discloses the use of cannabis in a rolling machine focuses on lubricating contact points in the rolling machine to prevent the adherence of cannabis resins to the contact points.

Given the known problems of processing sticky resinous hemp or related hemp-like plant materials though a cigarette rolling machine, a need exists for a method for processing the hemp or related hemp-like plant material that addresses the sticky resin. It would be advantageous if such a process could eliminate problems associated with the sticky resins thus allowing the hemp or hemp-like plant material to be processed through any conventional cigarette rolling machine as would ordinary tobacco.

SUMMARY OF THE INVENTION

According to one aspect of the invention, a process for hydrating plant material in a hydration machine for use in a cigarette rolling machine includes the steps of measuring the moisture level of the plant material, and if the moisture level is within a target range between about 9.5% by weight and about 11.5% by weight, bypassing the hydration machine and sealing the plant material into airtight drums and allowing the plant material to cure inside the airtight drums, but if the moisture level is outside of the target range, introducing the plant material into the hydration machine, and re-measuring the moisture level of the plant material at the exit of the hydration machine. If the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range, the process further includes sealing the plant material into airtight drums and allowing the plant material to cure inside the airtight drums. But if the moisture level of the plant material at the exit of the hydration machine is not within about 0.5% by weight of the target range, the process further includes re-introducing the plant material into the hydration machine, and repeating the re-measuring step as needed until the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range.

According to another aspect of the invention, a process for hydrating plant material in a hydration machine for use in a cigarette rolling machine includes the steps of measuring the moisture level of the plant material, introducing the plant material into the hydration machine, and determining initial hydration settings required to reach a target range of moisture between about 9.5% by weight and about 11.5% by weight at the exit of the hydration machine. The process further includes the steps of re-measuring the moisture level of the plant material at the exit of the hydration machine, and if the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range, removing the plant material from the hydration machine. But if the moisture level of the plant material at the exit of the hydration machine is not within about 0.5% by weight of the target range, the process further includes the steps of re-introducing the plant material into the hydration machine, and repeating the re-measuring step as needed until the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range.

According to a further aspect of the invention, a process for hydrating plant material in a hydration machine for use in a cigarette rolling machine includes the steps of measuring the moisture level of the plant material, introducing the plant material into the hydration machine, configuring hydration settings for the hydration machine to reach a target range of moisture between about 9.5% by weight and about 11.5% by weight at the exit of the hydration machine, and misting the plant material with one or more terpenes. The process further includes the steps of re-measuring the moisture level of the plant material at the exit of the hydration machine, and if the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range, removing the plant material from the hydration machine. But if the moisture level of the plant material at the exit of the hydration machine is not within about 0.5% by weight of the target range, the process further includes the steps of re-introducing the plant material into the hydration machine, re-configuring the hydration settings to reach the target range at the exit of the hydration machine, and repeating the re-measuring step as needed until the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a first portion of a process flowchart for an exemplary embodiment of the process for hydrating hemp for making hemp pre-rolls therefrom; and

FIG. 2 is a second portion of a process flowchart for an exemplary embodiment of the process for hydrating hemp for making hemp pre-rolls therefrom.

Other aspects and advantages of the present invention will become apparent upon consideration of the following detailed description, wherein similar structures have similar reference numerals.

DETAILED DESCRIPTION

The following detailed embodiments presented herein are for illustrative purposes. That is, these detailed embodiments are intended to be exemplary of the present invention for the purposes of providing and aiding a person skilled in the pertinent art to readily understand how to make and use of the present invention.

The process disclosed and claimed herein is not limited to any particular plant species or genus and may be applied to any type of plant material as may be needed before introducing the plant material into a cigarette rolling machine. Referring to FIG. 1, a process 100 is disclosed herein for hydrating, for example, hemp or hemp-like plant material (hereinafter “material”) for subsequent use in a conventional cigarette rolling machine. Though the process 100 can be accomplished on any conventional hydration machine, in one embodiment the hydration machine is for example without limitation a Hauni Hydration Machine manufactured by Hauni Körber Solutions, Hamburg, Germany. After completion of the process 100, the hydrated material can be successfully run through any conventional cigarette rolling machine, but in one embodiment the rolling machine is for example without limitation a Hauni Protos 80 cigarette rolling machine manufactured by Hauni Körber Solutions, Hamburg, Germany.

In one embodiment, the plant material starts the exemplary process 100 in standard agricultural storage sacks having a controllable opening at a bottom side for emptying and having handles or other extensions that allow the storage sack to be lifted by a forklift. The size of the storage sacks can be tailored for the particular size or rate of plant material to be hydrated. In one embodiment for example without limitation the storage sacks are in a size range capable of holding from about 300 pounds to about 500 pounds of hemp or other suitable plant material. In preparation for hydration the storage sacks containing hemp or other suitable plant material are arranged on pallets accessible to a forklift or other transporting machinery as may be known in the art.

Referring to the process flowcharts of FIGS. 1 and 2, at step 10 of the process 100 shown in FIG. 1, the plant material is tested for moisture level. Such tests for moisture level or content of the plant material can be accomplished as is known in the art using a standalone moisture measuring device or meter or a moisture measuring device or meter that is built into one of the machines used in the process of hydration and/or making of the cigarettes or hemp pre-rolls. Testing the plant material for moisture content prior to being added to the hydration machine allows the operator to know approximately the starting hydration settings needed on the machine. The moisture level is tested not only prior to being added to the machine but also during and after the hydration process. Hydration settings are determined by the measured levels of moisture content prior to, during, and after the process 100 as will be described more fully hereinbelow.

The target range for moisture content of the plant material is in a range between about 9.5% by weight and about 11.5% by weight, and preferably between about 10% by weight and about 11% by weight. If the plant material has a moisture level within the target range, then the plant material is ready for curing and no further hydration steps are required for preparation of the plant material. Referring to FIG. 1, in one embodiment if no further hydration is needed the process 100 skips to step 45 in FIG. 2, which is described hereinbelow. However, if the plant material has a moisture level outside of the target range it is subjected to steps 15 and beyond in FIGS. 1 and 2 wherein the plant material is hydrated in the hydration machine. Based on the moisture level in the plant material measured in step 10, at step 15 of FIG. 1 the hydration settings on the machine meaning the initial water flow rates for addition to the plant material are initially set.

In preparation for loading the plant material into the hydration machine, optionally at step 17, all surfaces of the hydration machine and other supplies or containers that come into contact with the plant material are cleaned, sanitized, and dried. In further preparation for loading the plant material into the hydration machine, in another optional step 18, a mister device that is pre-set at a predetermined flow rate is pre-loaded with one or more terpenes. Misting the plant material with the one or more terpenes may be used to add aroma and flavor as desired to the plant material, for example without limitation, hemp. The pre-loaded mister device is inserted into an opening of a hydration barrel of the hydration machine.

Still in preparation for loading the plant material into the hydration machine at step 20 of FIG. 1 a source of distilled water is connected with the hydration machine or distilled water is added to a sanitized water reservoir that the hydration machine draws from. As noted in step 15, all hydration settings (flow rates for water and the optional one or more terpenes for addition to the plant material) are initially set prior to operating the hydration machine based on the level of moisture measured at step 10.

At step 25 of FIG. 1 in one embodiment of the process 100 the plant material is placed into the hydration barrel of the hydration machine. In one embodiment one or more storage sacks are suspended, for example by forklift or other heavy lifting machinery, over the hydration barrel of the hydration machine and a knot at a bottom side of each storage sack is opened to release the plant material at a predetermined controlled rate into the hydration barrel. The predetermined controlled rate of release is dependent upon the size of the hydration barrel and may vary as the process progresses. As one storage sack is emptied a subsequent storage sack is moved into position to maintain the predetermined controlled rate of plant material release into the hydration barrel.

With the hydration machine operating, during the hydrating process at step 30 of FIG. 1 the moisture level of the plant material is measured again. Based on the type of hydrating machine, the quantity of plant material in the hydration machine, and the measured level of moisture relative to the target range of moisture, a calculation informs the operator whether the hydration settings (the water flow rate for addition to the plant material) need to be increased or decreased. The calculation is known in the art and may be performed manually or may be performed automatically by the hydration machine. At step 35 of FIG. 1, the calculation provides an indication to the operator of how to adjust the hydration settings meaning whether to increase, decrease, or maintain the hydration settings.

At step 40 of FIG. 2, hydrated material reaches the exit of the hydration machine and is again measured for moisture level. If the measured level of moisture at the exit of the hydration machine is within the target range, then at step 45 of FIG. 2 the plant material exiting the hydration machine is loaded into one or more drums and sealed airtight. The drums may be any sort of container that provide an airtight seal and may be of any size as required by the volume of the plant material being hydrated. In one embodiment for example without limitation the drums are standard 55 gallon plastic drums that include a lid providing an air tight seal.

If the plant material at the exit of the hydration machine has a level of moisture outside of the target range as measured in step 40 of FIG. 2, then depending on how far the measured moisture level differs from the target range, the plant material may or may not still be sealed into the one or more drums. In a first possibility, if the measured level of moisture is close to the target range, for example, if the level of moisture as measured in step 40 is within about 0.5% of the target range in terms of percentage moisture by weight and only a first portion of the plant material has so been measured, then a first option (Option 1 in FIG. 2) is followed. In the first option the hydration settings on the machine may be adjusted up or down as required to reach the target range, and the first portion of the plant material may be added to a drum to cure with plant material having a moisture within the target range as described with regard to step 50 of FIG. 2 hereinbelow. It is noted that there is no risk that the plant material that is outside of the target range for moisture will be used in the hemp pre-roll making process because all of the plant material is tested for moisture again before being fed into the cigarette rolling machine. So, any plant material outside of the target range would not be used in the cigarette rolling machine but would instead be run through the hydration machine again to reach the target range.

If the measured level of moisture is not close to the target range, for example, if the level of moisture as measured in step 40 is more than about 0.5% outside of the target range in terms of percentage moisture by weight, then a second option (Option 2 in FIG. 2) is followed. In the second option the hydration settings on the machine may be adjusted up or down as required to reach the target range, and the plant material is returned to step 25 of the process 100 to be loaded back into the hydration barrel to be run through the hydration machine again.

At step 50 of FIG. 2 the hydrated plant material inside the one or more sealed airtight drums is allowed to cure for a preferred period of about 24-48 hours prior to being used in the production of cigarettes, for example without limitation, hemp pre-rolls. If for some reason the plant material must be used sooner than the preferred period of 24-48 hours, then the plant material must be allowed to cure for a minimum of about 6 hours. On the other hand, if the plant material is not required for production within the preferred 24-48 hours, the plant material should not be allowed to cure for longer than about 120 hours. Plant material that has cured for more than 120 hours is introduced back into the hydration machine at step 25 to be hydrated once again.

After step 50 of FIG. 2, optionally at step 55, all surfaces of the hydration machine and other supplies or containers that come into contact with the plant material is cleaned and sanitized for example without limitation with alcohol and/or organic cleaning solution, and dried.

After curing the one or more sealed airtight drums containing the plant material are transferred to a production floor for making cigarettes, for example, hemp pre-rolls. Before being loaded into the cigarette rolling machine, at step 60 of FIG. 2, the plant material is again tested for moisture. If the measured moisture is outside of the target range the plant material is returned to the hydration machine to be rehydrated. However, if the measured moisture is within the target range the plant material is loaded into the cigarette rolling machine as is known in the art. Plant material processed using the process 100 can be run through any conventional cigarette rolling machine without any of the issues historically caused by the sticky resin of the plant material.

INDUSTRIAL APPLICABILITY

The process for hydrating plant material, for example, hemp for making hemp pre-rolls therefrom can be executed in industry using an ordinary hydration machine for making hemp pre-rolls on ordinary conventional cigarette rolling machines requiring no modifications or chemical treatments to contact points within the cigarette rolling machines.

Numerous modifications to the present invention will be apparent to those skilled in the art in view of the foregoing description. It is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. Accordingly, this description is to be construed as illustrative only of the principles of the invention and is presented for the purpose of enabling those skilled in the art to make and use the invention and to teach the best mode of carrying out same. The exclusive rights to all modifications which come within the scope of the appended claims are reserved. All patents, patent publications and applications, and other references cited herein are incorporated by reference herein in their entirety. 

We claim:
 1. A process for hydrating plant material in a hydration machine for use in a cigarette rolling machine, the process including the steps of: measuring the moisture level of the plant material; if the moisture level is within a target range between about 9.5% by weight and about 11.5% by weight, bypassing the hydration machine and sealing the plant material into airtight drums and allowing the plant material to cure inside the airtight drums; if the moisture level is outside of the target range, introducing the plant material into the hydration machine; re-measuring the moisture level of the plant material at the exit of the hydration machine, wherein if the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range, sealing the plant material into airtight drums and allowing the plant material to cure inside the airtight drums, but if the moisture level of the plant material at the exit of the hydration machine is not within about 0.5% by weight of the target range, re-introducing the plant material into the hydration machine; and repeating the re-measuring step as needed until the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range.
 2. The process of claim 1, wherein the hydration machine is configured to add moisture to the plant material in the form of water and one or more terpenes.
 3. The process of claim 1, further comprising the step of measuring the moisture level of the plant material within the hydration machine before the plant material reaches the exit of the hydration machine.
 4. The process of claim 3, further comprising the step of calculating required hydration settings to reach the target range at the exit of the hydration machine, and adjusting the hydration settings as required to reach the target range at the exit of the hydration machine.
 5. The process of claim 1, further comprising the steps of cleaning, sanitizing, and drying all surfaces of the hydration machine that come into contact with the plant material before introducing the plant material into the hydration machine.
 6. The process of claim 1, further comprising the steps of cleaning, sanitizing, and drying all surfaces of the hydration machine that come into contact with the plant material after the repeating step.
 7. The process of claim 1, further comprising the step of introducing the plant material into a cigarette rolling machine after the step of allowing the plant material to cure inside the airtight drums.
 8. The process of claim 1, wherein the step of allowing the plant material to cure inside the airtight drums further comprises allowing the plant material to cure inside the airtight drums for a curing time in a range between about 6 hours and 120 hours.
 9. The process of claim 8 wherein the curing time is in a range between about 24 hours and 48 hours.
 10. A process for hydrating plant material in a hydration machine for use in a cigarette rolling machine, the process including the steps of: measuring the moisture level of the plant material; introducing the plant material into the hydration machine; determining initial hydration settings required to reach a target range of moisture between about 9.5% by weight and about 11.5% by weight at the exit of the hydration machine; re-measuring the moisture level of the plant material at the exit of the hydration machine, wherein if the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range, removing the plant material from the hydration machine, but if the moisture level of the plant material at the exit of the hydration machine is not within about 0.5% by weight of the target range, re-introducing the plant material into the hydration machine; and repeating the re-measuring step as needed until the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range.
 11. The process of claim 10, further comprising the step of sealing the plant material into airtight drums after removing the plant material from the hydration machine.
 12. The process of claim 11, after the step of sealing the plant material into airtight drums further comprising the step of allowing the plant material to cure inside the airtight drums for a curing time in a range between about 6 hours and 120 hours.
 13. The process of claim 12 wherein the curing time is in a range between about 24 hours and 48 hours.
 14. The process of claim 10, wherein the hydration machine is configured to add moisture to the plant material in the form of water and one or more terpenes.
 15. The process of claim 10, further comprising the step of measuring the moisture level of the plant material within the hydration machine before the plant material reaches the exit of the hydration machine.
 16. The process of claim 15, further comprising the step of calculating updated required hydration settings to reach the target range at the exit of the hydration machine, and adjusting the hydration settings as required to reach the target range at the exit of the hydration machine.
 17. The process of claim 10, further comprising the steps of cleaning, sanitizing, and drying all surfaces of the hydration machine that come into contact with the plant material before introducing the plant material into the hydration machine.
 18. The process of claim 10, further comprising the steps of cleaning, sanitizing, and drying all surfaces of the hydration machine that come into contact with the plant material after the re-measuring step.
 19. A process for hydrating plant material in a hydration machine for use in a cigarette rolling machine, the process including the steps of: measuring the moisture level of the plant material; introducing the plant material into the hydration machine; configuring hydration settings for the hydration machine to reach a target range of moisture between about 9.5% by weight and about 11.5% by weight at the exit of the hydration machine; misting the plant material with one or more terpenes; re-measuring the moisture level of the plant material at the exit of the hydration machine, wherein if the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range, removing the plant material from the hydration machine, but if the moisture level of the plant material at the exit of the hydration machine is not within about 0.5% by weight of the target range, re-introducing the plant material into the hydration machine, re-configuring the hydration settings to reach the target range at the exit of the hydration machine, and repeating the re-measuring step as needed until the moisture level of the plant material at the exit of the hydration machine is within about 0.5% by weight of the target range.
 20. The process of claim 19, further comprising the steps of: sealing the plant material into airtight drums after removing the plant material from the hydration machine; and allowing the plant material to cure inside the airtight drums for a curing time in a range between about 24 hours and 48 hours. 